Audio device with power tool battery and external battery charger

ABSTRACT

An electrical component, such as, for example, a radio, MP3 player, audio component, battery charger, radio/charger, MP3 player/radio, MP3 player/charger, or MP3 player/radio/charger. The electrical component includes a housing and an electrical circuit supported by the housing. In some aspects, the electrical component is an audio component and the electrical circuit is an audio circuit. In other aspects, the electrical component is a battery charger and the electrical circuit is a charging circuit. In further aspects, the electrical component is an MP3 player and the electrical circuit is a MP3 circuit. In yet further aspects, the electrical component is an combination of any or all of a radio, battery charger, and MP3 player and the electrical component can include any combination or all of the audio, radio, and MP3 circuits. A battery may be connectable to the housing and electrically connectable the electrical circuit.

RELATED APPLICATIONS

This application is a continuation of co-pending patent application Ser.No. 12/605,482, filed on Oct. 26, 2009, which is a continuation ofco-pending patent application Ser. No. 10/926,744, filed on Aug. 26,2004, now U.S. Pat. No. 7,609,027, issued Oct. 27, 2009, which is acontinuation-in-part of patent application Ser. No. 10/291,868, filedNov. 8, 2002, now U.S. Pat. No. 6,982,541, issued Jan. 3, 2006, whichclaims the benefit of Provisional Patent Application Ser. No.60/379,068, filed May 9, 2002 and Provisional Patent Application Ser.No. 60/344,431, filed on Nov. 9, 2001. patent application Ser. No.10/926,744 also claims the benefit of Provisional Patent ApplicationSer. No. 60/523,541, filed Nov. 19, 2003, and Provisional PatentApplication Ser. No. 60/540,313, filed Jan. 28, 2004. The entirecontents of all of the above applications are hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates to electrical components and, moreparticularly, to, for example, a radio, a MP3 player, an audiocomponent, a battery charger, a radio/charger, a MP3 player/radio, a MP3player/charger or a MP3 player/radio/charger, and a battery chargerselectively connectable to electrical components.

BACKGROUND OF THE INVENTION

An electrical component, such as, for example, a radio, an audiocomponent, a battery charger, a radio/charger or a MP3 player includes acomponent housing supporting an electrical circuit, such as an audiocircuit, a charging circuit, a MP3 circuit, respectively. In someelectrical components, such as the radio, a battery is electricallyconnectable to the audio circuit to operate the audio circuit to produceaudio signals. In some electrical components, such as the batterycharger, a battery is electrically connectable to the charging circuitto be charged by the charging circuit. In other electrical components,such as the MP3 player, a battery is electrically connectable to the MP3circuit to operate the MP3 circuit to produce MP3 audio signals.

SUMMARY OF THE INVENTION

Typically, the above-described electrical components can onlyaccommodate one type or size of battery in the electrical component'sbattery receptacle. For example, the construction of the receptacle maylimit the battery size. Also, the position and structure of the assemblyto connect the battery to the electrical component may limit the batterysize.

Also, with the above-described electrical components, the battery isdifficult to remove from the battery receptacle.

In addition, the above-described electrical components, the battery isfree to move within the battery receptacle and, therefore, may becomedisconnected during work site operations.

Further, existing radios, MP3 players and other audio components are notuseable with a slide-on power tool battery.

Also, the above-described electrical components lack storage foraccessories useable with the electrical component, such as, for example,a cell phone and an auxiliary audio component.

In addition, the electrical components are not rugged and may be damagedat a work site during normal and/or adverse working conditions.

In some constructions and in some aspects, the present inventionprovides an electrical component, such as, for example, a radio, anaudio component, a battery charger, a radio/charger, a MP3 player, a MP3player/radio, a MP3 player/charger or a MP3 player/radio/charger thatsubstantially alleviates one or more of the above-described and otherproblems with existing electrical components. More particularly, in someconstructions and in some aspects, the invention provides an electricalcomponent, which accommodates batteries of different sizes. Also, insome constructions and in some aspects, the invention provides anelectrical component in which the battery is biased out of the batteryreceptacle to move the battery to a more accessible position forremoval. In addition, in some constructions and in some aspects, theinvention provides an electrical component in which the battery islocked in a position relative to the electrical component housing.Further, in some constructions and in some aspects, the inventionprovides an electrical combination including an audio component and aslide-on power tool battery connectable to the audio component.

Also, in some constructions and in some aspects, the invention providesa combination including an electrical component and an accessory bagconnectable to the electrical component to store accessories useablewith the electrical component. In addition, in some constructions and insome aspects of the invention, the invention provides an electricalcomponent having a rugged, durable construction and/or structure.Further, in some constructions and in some aspects, the inventionprovides a MP3 player in which the battery is locked in a positionrelative to the MP3 player housing.

In addition, in some constructions and in some aspects, the inventionprovides a MP3 player having a rugged, durable construction and/orstructure. Further, in some constructions and in some aspects, theinvention provides a combination including a MP3 player and a slide-onpower tool battery connectable to the MP3 player. Also, in someconstructions and in some aspects, the invention provides an electricalcomponent with a MP3 circuit and a charging circuit.

In addition, in some constructions and in some aspects, the inventionprovides a MP3 player including a housing, a MP3 circuit for producing aMP3 audio signal, the MP3 circuit being supported by the housing, abattery being supportable by the housing and electrically connectable tothe MP3 circuit, and locking assembly operable to lock the battery in aposition relative to the housing.

Further, in some constructions and in some aspects, the inventionprovides a MP3 player including a housing, a blow-molded base connectedto the housing, a handle connected to the housing and to the base, thehandle having an upper portion positioned above the housing a sideportion positioned to one side of the housing, the handle beingconfigured to absorb impacts to the housing, and a MP3 audio circuit forproducing a MP3 audio signal, the MP3 audio circuit being supported bythe housing.

Also, in some constructions and in some aspects, the invention providesan electrical combination including a MP3 player including a housinghaving a support portion and a MP3 audio circuit for producing a MP3audio signal, the MP3 audio circuit being supported by the housing, anda slide-on power tool battery supportable by the support portion of thehousing, the slide-on power tool battery being operable to power a powertool.

In addition, in some constructions and in some aspect, the inventionprovides a MP3 player including a housing, a MP3 audio circuit supportedby the housing and operable to produce a MP3 audio signal, the MP3 audiocircuit being electrically connectable to a power source, and a chargingcircuit supported by the housing and connectable to a power tool batteryand to a power source and operable to charge the battery, the power toolbattery being operable to power a power tool.

Further, in some constructions and in some aspects, the inventionprovides an electrical component, such as an audio component, includingan audio component housing, a circuit supported by the housing andoperable to produce an audio signal, a battery being connectable to thehousing and electrically connectable to the circuit, and a lockingassembly operable to lock the battery in a position relative to thehousing. The housing may define a receptacle, and the battery may besupportable in the receptacle. The audio component may further include abiasing member positioned in the receptacle, and the biasing memberpreferably biases the battery out of the receptacle. Preferably, thebattery is a power-tool battery operable to power a power tool.

The locking assembly may include a locking projection on one of thebattery and the housing and a recess defined by the other of the batteryand the housing. Preferably, the locking projection is movable between alocked position, in which the projection engages the recess to lock thebattery in a position relative to the housing, and an unlocked position,in which the battery is movable relative to the housing. The lockingassembly may include an actuator operable to move the locking projectionbetween the locked position to the unlocked position and/or between thelocked position and the unlocked position. The locking assembly may alsoinclude a biasing member biasing the locking projection toward thelocked position. Also, in some constructions and in some aspects, theinvention provides an electrical component generally having a housingand a battery charger selectively connectable to the housing.

In addition, in some constructions and in some aspects, the inventionprovides an electrical component generally having a battery charger, afirst battery for powering the electrical component and a second batteryelectrically connected to the battery charger, the battery charger beingoperable to charge the second battery.

Also, the invention provides an electrical component, such as a batterycharger, including a charger housing, a charging circuit supported bythe housing and selectively connectable with a power source, a batterybeing connectable to the housing and electrically connectable with thecharging circuit such that the charging circuit is selectively operableto charge the battery, and a locking assembly operable to lock thebattery in a position relative to the housing.

In addition, the invention provides an electrical component including ahousing defining a receptacle, an electrical circuit supported by thehousing, a battery being supportable in the receptacle and connectableto the electrical circuit, and a biasing member operable to bias thebattery out of the receptacle to an ejected position. The biasing membermay be supported within the receptacle. The housing may also include acover selectively closing an open end of the receptacle. The cover mayinclude a second biasing member selectively biasing the battery into thereceptacle.

In some constructions, the electrical component may be an audiocomponent, and the electrical circuit may be an audio circuit forproducing an audio signal. In some constructions, the electricalcomponent may be a battery charger, and the electrical circuit may be acharging circuit connectable to the battery and operable to charge abattery. The battery may be a power tool battery, such as, a slide-onpower tool battery or a tower power tool battery.

The electrical component may also include an electrical connectorassembly for connecting the battery to the electrical circuit. Theelectrical connector assembly may be supported in the receptacle. Theelectrical connector assembly may include a support portion supportingthe battery. The support portion may be movable relative to the housing,and a biasing member may bias the support portion toward an open end ofthe receptacle to bias the battery to the ejected position.

The electrical component may also include a locking assembly operable tolock the battery in a position relative to the housing. In someconstructions, the locking assembly may be a cover supported by thehousing and selectively closing the open end of the receptacle to lockthe battery in the receptacle.

In some constructions, the locking assembly may include a lockingprojection on one of the battery and the electrical connector assemblyand a recess defined by the other of the battery and the electricalconnector assembly. The locking projection may be movable between alocked position, in which the projection engages the recess to lock thebattery in a position relative to the electrical connector assembly, anda unlocked position, in which the battery is movable relative to theelectrical connector assembly.

In some constructions, the locking assembly may include a lockingprojection on one of the electrical connector assembly and the housingand a recess defined by the other of the electrical connector assemblyand the housing. The locking projection may be movable between a lockedposition, in which the projection engages the recess to lock theelectrical connector assembly in a position relative to the housing, andan unlocked position, in which the electrical connector assembly ismovable relative to the housing. In these constructions, the lockingassembly may also include an actuator movable between a locked positionand an unlocked position. The locking projection is in the lockedposition thereof when the actuator is in the locked position thereof,and the locking projection is in the unlocked position thereof when theactuator is in the unlocked position thereof.

Further, the invention provides an electrical combination including anelectrical component, such as an audio component, including an audiocomponent housing having a support portion, and a circuit supported bythe housing and operable to produce an audio signal, and a slide-onpower tool battery supportable by the support portion of the housing andoperable to power a power tool.

Also, the invention provides an electrical component including a housingdefining a receptacle, an electrical circuit supported by the housing,and a connector assembly movably supported by the housing and connectinga battery to the electrical component. The battery may be one of a firstbattery having a first dimension and a second battery having seconddimension. The first dimension is different than the second dimension.The receptacle may selectively receive one of the first battery and thesecond battery. The receptacle may accommodate only one of the firstbattery and the second battery at a time. The connector assembly ispreferably movable relative to the housing to selectively accommodatethe first battery and the second battery.

The connector assembly may include a support portion movable relative tothe housing, and the battery is preferably supportable on the supportportion. One of the battery and the support portion may include aprojection and the other of the battery and the support portion maydefine a recess. The projection is preferably engageable in the recessto connect the battery to the connector assembly.

The connector assembly may also include a connector terminal assemblyconnected to the electrical circuit and movable relative to the housing.The battery may include a battery terminal assembly, and the batteryterminal assembly is preferably connectable to the connector terminalassembly to connect the battery to the electrical circuit. The supportportion and the connector terminal assembly may be preferably movablerelative to the housing.

In addition, the invention provides an electrical component including ahousing defining a receptacle having an open end, the housing includes acover selectively closing the open end of the receptacle, and anelectrical circuit supported by the housing, a first battery beingsupportable in the receptacle and connectable to the electrical circuit,the first battery having a first dimension, a second battery beingsupportable in the receptacle and connectable to the electrical circuit,the second battery having a second dimension, the first dimension beingdifferent than the second dimension, the receptacle selectivelyreceiving one of the first battery and the second battery.

The electrical component may further include a movable support portionpositioned in the receptacle for selectively supporting one of the firstbattery and the second battery. One of the support portion and the oneof the first battery and the second battery may include a projection andthe other of the support portion and the one of the first battery andthe second battery may define a recess, the projection may be engageablein the recess to support the one of the first battery and the secondbattery on the support portion. The movable support portion may includea track with a protrusion and a recess and at least one electricalconnector thereon. The track and electrical connector may be movable inrelation to the housing. The electrical component may further include alocking assembly supported by the housing and operable to lock one ofthe first battery and the second battery to the housing.

Further, the invention provides a combination including an electricalcomponent having a housing defining a well portion in a rear of thehousing, and an electrical circuit supported by the housing, and anaccessory bag selectively connectable to the housing at least partiallywithin the well portion.

The accessory bag may include a handle. The accessory bag may define anopening to facilitate passing of electrical cords from inside theaccessory bag to outside the accessory bag. The accessory bag mayfurther include at least one flap for selectively covering the opening.The accessory bag may alternatively include at least one zipper forselectively closing the opening.

The combination may further include at least one housing connectorsupported on the housing and at least one bag connector supported on theaccessory bag. The housing connector and the bag connector may beoperable to selectively connect to one another to selectively supportthe accessory bag on the housing. The combination may further include anelectrical plug supported on the housing and electrically connected tothe electrical circuit.

Independent features and independent advantages of the invention willbecome apparent to those skilled in the art upon review of the detaileddescription, claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of an electrical component embodyingthe invention.

FIG. 2 is a schematic diagram of an electrical circuit for theelectrical component.

FIG. 3 is an exploded rear perspective view of a portion of theelectrical component shown in FIG. 1.

FIG. 4 is a rear perspective view of a portion of the electricalcomponent shown in FIG. 1.

FIG. 5 is a perspective view of a battery and a portion of a power tool.

FIG. 6 is a top perspective view of an electrical connector assemblyshown in FIG. 3.

FIG. 7 is a bottom perspective view of the electrical connector assemblyshown in FIG. 6.

FIG. 8 is an exploded top perspective view of the electrical connectorassembly shown in FIG. 6.

FIG. 9 is a bottom perspective view of an alternative construction of anelectrical connector assembly for the electrical component.

FIG. 10 is an exploded top perspective view of the electrical connectorassembly shown in FIG. 9.

FIG. 11 is a perspective view of an alternative construction of abiasing assembly for the electrical component.

FIG. 12 is a side elevation view of a battery and an alternativeconstruction of a support portion for the electrical component.

FIG. 13 is a rear perspective view of an alternative construction of anelectrical component embodying the invention.

FIG. 14 are views of an accessory bag for use with the electricalcomponent.

FIG. 15 is a front view of a display for the electrical component.

FIG. 16 is a front perspective view of the electrical component shown inFIG. 13.

FIG. 17 is a side view of another alternative construction of anelectrical component and a separate battery charger embodying aspects ofthe invention.

FIG. 17A is a side view of another alternative construction of anelectrical component, shown with a battery charging circuit positionedalong and in series with a power cord.

FIG. 17B is a side view of another alternative construction of anelectrical component, shown with a battery charging circuit positionedin a wall plug of a power cord.

FIG. 18 is a side cross-sectional view of a portion of the electricalcomponent shown in FIG. 1 illustrating the connection of the handle andthe housing.

FIG. 19 is an exploded perspective view of a lower portion of theconnection shown in FIG. 18.

FIG. 20 is an exploded perspective view of an upper portion of theconnection shown in FIG. 18.

FIG. 21 is a rear perspective view of the electrical component shown inFIG. 1, shown with a power cord.

FIG. 22 is a partial side view of the electrical component and the powercord shown in FIG. 21, shown with a portion cut away.

FIG. 23 is a partial side view of the electrical component and the powercord shown in FIG. 21.

FIG. 24 is a perspective view of a portion of the electrical componentand the power cord shown in FIG. 21 and illustrating the power corddisconnected from the electrical component.

FIG. 25 is a cross-sectional view taken generally along line 25-25 inFIG. 22.

FIG. 26 is a perspective view of an alternative construction of thepower cord shown in FIG. 21.

FIG. 27 is a perspective view of the power cord shown in FIG. 26 withportions cut away.

FIG. 28 is a front perspective view of the electrical component, shownwith a MP3 player.

FIG. 29 is a front perspective view of the electrical component, shownwith a MP3 player.

FIG. 30 is a side view of an alternative construction of an electricalcomponent, shown with a plurality of power cells.

FIG. 31 is a side view of an alternative construction of an electricalcomponent, shown with a plurality of power cells.

FIG. 32 is a side view of an alternative construction of an electricalcomponent, shown with a power cell housing and a plurality of powercells positioned within the power cell housing.

FIG. 33 is a side view of an alternative construction of an electricalcomponent, shown with a power cell housing, a plurality of power cellspositioned within the power cell housing and the power cell housing andthe power cells being positioned along and in series with the powercord.

FIG. 34 is a front perspective view of an alternative construction of anelectrical component.

FIG. 35 is a rear perspective view of the electrical component shown inFIG. 34.

FIG. 36 is a front view of the electrical component shown in FIG. 34.

FIG. 37 is a right side view of the electrical component shown in FIG.34.

FIG. 38 is a left side view of the electrical component shown in FIG.34.

FIG. 39 is a top view of the electrical component shown in FIG. 34.

FIG. 40 is a bottom view of the electrical component shown in FIG. 34.

FIG. 41 is a front perspective view of the electrical component shown inFIG. 34, shown with a cover pivoted to an open position.

FIG. 42 is a front view of the electrical component shown in FIG. 34,shown with the cover pivoted to the open position.

FIG. 43 is a front perspective view of the electrical component shown inFIG. 34, shown with the cover pivoted to an open position and a batteryextending outwardly of a battery receptacle coverable by the cover.

FIG. 44 is a front perspective view of the electrical component shown inFIG. 34, shown with a battery extending outwardly from the batterycharger.

FIG. 45 is a front perspective view of the electrical component shown inFIG. 34, shown with the cover pivoted to the open position and withoutbatteries connected to the electrical component.

FIG. 46 is a partially broken, bottom perspective view of the batterycharger and a connecting assembly of the electrical component shown inFIG. 34, shown in a disconnected condition.

FIG. 47 is a front perspective view of the electrical component shown inFIG. 34, shown with the battery charger extended outwardly from theelectrical component.

FIG. 48 is a front perspective view of the electrical component shown inFIG. 34, shown with a control portion extended outwardly from theelectrical component.

FIG. 49 is a plurality of front perspective views of an alternativeconstruction of an electrical component.

FIG. 50 is a front perspective view of another alternative constructionof an electrical component.

FIG. 51 is a rear perspective view of the electrical component shown inFIG. 50, shown with a battery charger removed.

FIG. 52 is a front perspective view of yet another alternativeconstruction of an electrical component.

FIG. 53 is a rear perspective view of the electrical component shown inFIG. 52, shown with two battery chargers removed.

FIG. 54 is a front perspective view of another alternative constructionof an electrical component.

FIG. 55 is a front perspective view of yet another alternativeconstruction of an electrical component.

FIG. 56 is a pair of front perspective views of another alternativeconstruction of an electrical component, shown in an open condition andin a closed condition.

Before at least one embodiment of the invention is explained in detail,it is to be understood that the invention is not limited in itsapplication to the details of the construction and arrangements of thecomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or carried out in various ways. Also, it is understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless limited otherwise, the terms“connected,” “coupled,” and variations thereof herein are used broadlyand encompass direct and indirect connections and couplings. Inaddition, the terms “connected” and “coupled” and variations thereof arenot restricted to physical or mechanical connections or couplings.

DETAILED DESCRIPTION

FIG. 1 illustrates an electrical component 20, such as a combinationradio and power tool battery charger. It should be understood that, inother constructions, the electrical component 20 may include anotheraudio component, such as, for example, a tape player, a CD player, a MP3player (discussed in greater detail below), a jukebox, etc. It shouldalso be understood that, in some constructions and for some aspects, theelectrical component 20 may be another electrical component, such as,for example, an audio component, a battery charger, a power tool, a cellphone charger, a power supply for other electrical equipment, etc.

The electrical component 20 includes an electrical component housing 24and an electrical circuit 28 (schematically illustrated in FIG. 2)supported by the housing 24. In the illustrated construction, theelectrical circuit 28 is a combination radio and battery chargingcircuit having an audio circuit portion 29, operable to produce an audiosignal, and a charging circuit portion 30, operable to charge a battery.It should be understood that, in other constructions and for someaspects, the electrical circuit 28 may be any type of electricalcircuit, such as, for example, an audio circuit for producing an audiosignal or a charging circuit for charging a battery.

The electrical circuit 28 is connectable to a power source, whichsupplies power to the electrical circuit 28. The power source mayinclude an AC power source, such as line power (through a power cord 31(discussed in greater detail below, see FIG. 21)), or a DC power source,such as a battery. In the illustrated construction, the audio circuitportion 29 is selectively powered by an AC power source or by a DC powersource. The AC power source can be the primary power source for theelectrical circuit 28, and the DC power source can be a secondary orback-up power source. Also, in the illustrated construction, thecharging circuit portion 30 is connectable to a power source to charge abattery. In some constructions, an AC power source may not be included,in which case, the DC power source is the sole power source and theelectrical component is powered by the DC power source only.

As explained below in more detail, the electrical circuit 28 includes apower amplifier circuit portion for amplifying an input, such as asignal from an auxiliary component, to the audio circuit portion 29. Theelectrical circuit 28 also includes a power supply portion which may beconnected through a power outlet on the electrical component 20 to powerother electrical devices (including the auxiliary component).

As shown in FIG. 1, the housing 24 includes a base portion 32, a mainportion 36, and a handle portion 40. The base portion 32, the mainportion 36, and the handle portion 40 are designed to have impactabsorbing characteristics which protect the electrical component 20 fromimpacts at a jobsite, such as from falling from a height or havinganother object impact the electrical component 20, which might normallydamage the elements of the electrical component 20, such as, forexample, the elements of the electrical circuit 28, and/or create anelectrical hazard in the electrical component 20. For example, thehousing 24 may be formed of energy/impact absorbing materials, such as,for example, high-density polyethylene (HDPE), and/or formed withenergy/impact absorbing structures, such as, for example, bars, baseedges, bumpers, bushings, ribs, honeycombs, energy-absorbing shapes,etc. In the illustrated construction, at least the base portion 32 isblow-molded from an energy/impact absorbing material, such as, forexample, high-density polyethylene (HDPE).

As shown in FIG. 3, the housing 24 defines a receptacle 44 having aclosed end 48, defined by a bumper 52 (discussed below), an open end 56,and side walls 60 extending from the closed end 48 to the open end 56. Abattery 64 is inserted into the receptacle 44 along an insertion axis68. The battery 64 is electrically connected to the electrical circuit28 to, in the illustrated construction, selectively provide power to theelectrical circuit 28 or be charged by the charging circuit portion 30of the electrical circuit 28. However, the battery 64 is monitored byand disconnected from the electrical circuit 28, as necessary, toprevent deep discharge of the battery 64. Such deep discharge preventionis described in U.S. Pat. No. 6,211,652, issued on Apr. 3, 2001, whichis hereby incorporated by reference.

For purposes of description, “forward” is defined as being in thedirection of the open end 56 along the insertion axis 68. Similarly,“rearward” is defined relative to “forward” as being in the direction ofthe closed end 48 and away from the open end 56 along the insertion axis68.

As shown in FIG. 4, the housing 24 includes a cover 66 pivotallyconnected to the base portion 32 for selectively closing the open end 56of the receptacle 44. A latching member 67 is selectively lockable tothe main portion 36 (see FIG. 1) to lock the cover 66 in a closedposition (shown in FIG. 1). A cover biasing member 69 is mounted on theinterior surface of the cover 66. When the cover 66 is closed, thebiasing member 69 engages and biases the battery 64 (see FIG. 3) intothe receptacle 44 to maintain proper electrical connection, as describedbelow in more detail, during normal operations or during and after animpact condition.

As shown in FIG. 5 and in the illustrated construction, the battery 64is a slide-on power tool battery 70 operable to power a power tool 71,such as, for example, a drill, a circular saw, a reciprocating saw, etc.The slide-on battery 70 is slidably mountable on the power tool 71. Inthe illustrated construction, the slide-on battery 70 includes a batteryhousing 80 supporting a number of battery cells (not shown), a batteryterminal assembly 84, a battery support portion 88, and locking membersor locking tabs 92 (one shown). The terminal assembly 84 facilitateselectrical connection between the battery cells and a motor (not shown)of the power tool 71 and/or the circuit 28 of the electrical component20.

In the illustrated construction, the support portion 88 of the slide-onbattery 70 has a generally C-shaped cross-section provided by grooves104 and rails 108 which extend parallel to the insertion axis 68 (seeFIG. 3). The locking tabs 92 are supported in the C-shaped supportportion 88 and are movable perpendicular to the insertion axis 68 bydepressing locking tab actuators or buttons 112 (one shown).

In the illustrated construction, the power tool 71 includes a generallyT-shaped power tool support portion 116 and a power tool terminalassembly 100. The support portion 88 of the battery 70 is complementaryto the support portion 116 of the power tool 71, and, therefore, thecomplementary components physically and electrically connect the battery70 to the power tool 71. The locking tabs 92 engage in recesses (notshown) on the power tool support portion 116 to provide a batterylocking assembly between the battery 70 and the power tool 71.

It should be understood that, in other constructions (not shown), thebattery 70 may be a different type of slide-on power tool battery, suchas, for example, a battery having a T-shaped cross-section. In suchconstructions, the power tool and the electrical component would have acomplementary C-shaped cross-section support portion.

It should also be understood that slide-on batteries have a variety ofsizes depending on the number and orientation of the cells in thebattery housing. In the illustrated construction, the slide-on battery70 has a first dimension, such as an axial length, and another slide-onbattery (shown in phantom in FIG. 5) has a second dimension, such as asecond axial length, which is different than that of the first slide-onbattery 70.

In addition, it should be understood that the electrical component 20 isusable with batteries having different battery chemistries (i.e.,Lithium-based chemistries (Li, Li-ion, etc.), Nickel Metal Hydride(NiMH), Nickel Cadmium (NiCd), etc.). The electrical circuit 28 and thecharging circuit portion 30 may include identification circuitry andstructure necessary to identify the chemistry of the battery 70 toensure proper charging and operation of the battery 70.

In an alternative construction and in some aspects, the electricalcomponent 20 is usable with a tower power tool battery 72 (see FIG. 12),discussed below in more detail. Also, in other constructions (not shown)and in some aspects, the electrical component 20 may be used with othertypes and sizes of batteries.

As shown in FIGS. 6 and 7, the housing 24 supports an electricalconnector assembly 144 positioned in the receptacle 44. The connectorassembly 144 includes a support portion 148, a body portion 152, aterminal assembly 156, biasing members 160, the bumper 52, and a lockingassembly 168. In the illustrated construction, the support portion 148and the terminal assembly 156 move within the receptacle 44 relative tothe housing 24, in a direction parallel to the insertion axis 68 (seeFIG. 3), upon the insertion and the ejection of the battery 70 into andout of the receptacle 44, respectively. In part, this movementaccommodates batteries of different sizes.

As shown in FIG. 7, the support portion 148 of the connector assembly144 is substantially similar to the support portion 116 of the powertool 71 (see FIG. 5) with which the battery 70 is normally used. Thesupport portion 148 includes grooves 172 and protrusions 176 whichextend parallel to the insertion axis 68 (see FIG. 3). The grooves 172and protrusions 176 of the connector assembly 144 are complementary tothe grooves 104 and rails 108 of the battery 70 and, therefore, supportthe battery 70 on the support portion 148.

The terminal assembly 156 is mounted on the support portion 148 and iselectrically connectable to the battery terminal assembly 84 to connectthe battery cells to the electrical circuit 28. In the illustratedconstruction, the terminal assembly 156 is movable with the supportportion 148 relative to the housing 24.

As shown in FIGS. 7 and 8, the support portion 148 is mounted on theunderside of the body portion 152 and guide channels 184 are provided onthe body portion 152. The biasing members 160 are positioned in thechannels 184. The channels 184 maintain the alignment of the biasingmembers 160 during compression and expansion of the biasing members 160.The biasing members 160 bias the support portion 148 and the bodyportion 152 (and the battery 70, when supported on the support portion148) toward the open end 56 of the receptacle 44. In the illustratedconstruction, the biasing members 160 are compression springs. In otherconstructions (not shown), the biasing members 160 may be other types ofsprings or other structure, such as, for example, elastomeric material.

In the construction shown in FIG. 8, the locking assembly 168 locks thesupport portion 148, the body portion 152, and the attached battery 70in an axial position relative to the housing 24. The locking assembly168 includes a housing 228, a biasing assembly 230, an actuator 236, andlocking protrusions 240 (one shown). The locking assembly 168 has atleast one locked condition (shown in FIG. 6), in which the supportportion 148 and attached battery 70 are locked in an axial positionrelative to the housing 24, and an unlocked condition, in which thesupport portion 148 and attached battery 70 are axially movable relativeto the housing 24.

The housing 228 defines (see FIG. 8) a first path 256, parallel to theinsertion axis 68 and along which the actuator 236 travels, and a secondpath 260, generally perpendicular to the insertion axis 68 and alongwhich the locking protrusions 240 travel. The housing 228 definesopenings 264 (one shown) in both sides through which the lockingprotrusions 240 selectively protrude.

The biasing assembly 230 includes an actuator biasing member 265 and alocking protrusion biasing member 266. The actuator biasing member 265lies in the first path 256 and biases the actuator 236 toward the openend 56 of the receptacle 44 and toward a position corresponding to alocked condition of the locking assembly 168. The locking protrusionbiasing member 266 lies in the second path 260 and, in the illustratedconstruction, biases the locking protrusions 240 toward the retracted,unlocked position.

The actuator 236 controls movement of the locking protrusions 240. Inthe illustrated construction, the actuator 236 biases the lockingprotrusions 240 toward the locked position and allows the lockingprotrusions 240 to move to the unlocked position. The actuator 236 ispositioned between the locking protrusions 240 and has a wide portion268 and a narrow portion 272. The locking protrusion biasing member 266biases the locking protrusion 240 inward toward the actuator 236. Thelocking protrusions 240 lie in the second path 260 and are operable toselectively extend out of the openings 264 (a locked position) andretract into the openings 264 (the unlocked position).

In the locked position, the wide portion 268 of the actuator 236contacts the locking protrusions 240 and moves the locking protrusions240 out of the openings 264 against the biasing force of the lockingprotrusion biasing members 266. In the locked position, the lockingprotrusions 240 prevent the end walls 188 of the guide channels 184 frommoving forward of the locking protrusions 240, and, therefore, limit themovement of the support portion 148 and body portion 152 (and thebattery 70, when supported on the support portion 148) toward the openend 56 of the receptacle 44. Thus, the support portion 148, the bodyportion 152, and the battery 70 are locked in an axial position relativeto the electrical component housing 24. In the locked condition of theconnector assembly 144, the support portion 148 is capable of moving inthe space between the bumper 52 and the locking protrusions 240. Thismovement enables the electrical component 20 to receive different sizedbatteries 70 within the receptacle 44.

As the battery 70 is inserted, the support portion 148 is movedrearwardly until the openings 264 are uncovered. When this occurs, theactuator 236 moves forwardly and moves the locking protrusions 240 toextend out of the openings 264. The locking protrusions 240 extend intothe axial path of the guide channels 184 and prevent the support portion148 and the body portion 152 (and the battery 70, when supported on thesupport portion 148) from moving forwardly beyond the position of thelocking protrusions 240.

To unlock the locking assembly 168, the actuator 236 is pressedinwardly. As the actuator 236 is depressed against the actuator biasingmember 265, the wide portion 268 of the actuator 236 slides out ofcontact with the locking protrusions 240. The locking protrusion biasingmembers 266 move the locking protrusions 240 inwardly as the narrowportion 272 slides between the locking protrusions 240, and the lockingprotrusions 240 retract into the openings 264, eventually terminatingcontact with the end walls 188 (the unlocked position). This allows thesupport portion 148 to move towards the open end 56 of the receptacle 44to place the battery 70 in a more readily accessible position forremoval from the receptacle 44 (the ejected position). In theillustrated construction, the biasing members 160 move the supportportion 148 and the battery 70 forwardly to the more accessibleposition.

In other constructions (not shown), the locking assembly 168 may be aratchet-type locking assembly having more than one axially-spaced lockedposition of the support portion 148 relative to the housing 24. As thebattery is inserted, the support portion 148 may be moved through thelocked positions to the most appropriate locked position based on, forexample, the length of the battery 70.

In other constructions (not shown), the actuator and the lockingprotrusion may cooperate in another manner such as through cooperatingstructure, such as, for example, a pin and a groove.

In other constructions, for example, the actuator and the lockingprotrusion may operate in a different manner, such as, the actuator maymove the locking protrusion to the unlocked position and the actuatormay allow the locking protrusion to move to the locked position.

In other constructions (not shown), the actuator 236 may move in adifferent manner, such as, for example, vertically, laterally, orpivotally, to allow movement of and/or to move the locking protrusions240 between the locked position and the unlocked position.

In other constructions (not shown), the locking protrusions 240 may movein a different manner, such as, for example, vertically, axially, orpivotally, between the locked position and the unlocked position.

An alternative construction of an electrical connector assembly 144A isillustrated in FIGS. 9 and 10. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-8. Common elements are identified bythe same reference numbers “A”.

In the previously-described construction (FIGS. 6-8), the electricalconnector assembly 144 is locked to the housing 24 and the battery 70 issupported on the connector assembly 144. In this alternativeconstruction, the battery 70 is locked to the electrical connectorassembly 144A. As shown in FIG. 9, the electrical connector assembly144A is supported by the housing 24A and is positioned in the receptacle44A. The electrical connector assembly 144A is operable to support thebattery 70 in the receptacle 44A, lock the battery 70 relative to thehousing 24A, and electrically connect the battery 70 to the electricalcircuit 28.

In the illustrated construction, the connector assembly 144A includes amounting plate 280, latching members or locking members 284, a lockingmember biasing member or spring 288 (see FIG. 10), an actuator 292, anactuator biasing member or spring 296 (see FIG. 10), a support portion300, and a terminal assembly 304. The locking members 284, actuator 292,and support portion 300 are mounted to the mounting plate 280, and theterminal assembly 304 is mounted to the support portion 300. Themounting plate 280 is mounted to the housing 24A. The connector assembly144A has a locked condition, in which the battery 70 is locked to theelectrical connector assembly 144A to lock the battery 70 in a positionrelative to the housing 24A, and an unlocked condition, in which thebattery 70 is movable relative to the electrical connector assembly144A.

The support portion 300 of the connector assembly 144A is complementaryto the battery support portion 88 so that the battery 70 is supportableon the support portion 300. The support portion 300 includes grooves 308and protrusions 312 which extend parallel to the insertion axis 68A. Thegrooves 308 and protrusions 312 of the support portion 300 arecomplementary to the grooves 104 and rails 108 of the battery 70, and,therefore, the battery 70 is supported on the connector assembly 144Aand electrically connected (by the terminal assembly 304) to theelectrical circuit 28A when the battery 70 is inserted into thereceptacle 44A.

As shown in FIG. 10, the spring 288 biases the locking members 284inwardly toward each other. Each locking member 284 includes a recess320, which receives one of the locking tabs 92 (see FIG. 5) of thebattery 70 as the battery 70 is inserted into the receptacle 44A andonto the support portion 300. The battery 70 locks to the electricalconnector assembly 144A when the locking tabs 92 engage the recesses320.

The actuator 292 of the electrical connector assembly 144A is positionedbetween the locking members 284 and travels along a path 324 parallel tothe insertion axis 68. The actuator 292 has a wide portion 332 and anarrow portion 336 positionable between the locking members 284. Theactuator 292 is biased to a position corresponding to a locked conditionof the connector assembly 144A (and to the locked position of thelocking members 284) by the actuator spring 296. When the actuator 292is in the position corresponding to the locked condition, the wideportion 332 of the actuator 292 is between the locking members 284, andthe locking members 284 are biased laterally outwardly to engage thelocking tabs 92 of the battery 70.

When the actuator 292 is depressed, the narrow portion 336 is positionedbetween the locking members 284. The locking members 284 move inwardlyunder the biasing force of the spring 288 to disengage from the lockingtabs 92 of the battery 70 (the unlocked position of the locking members284 and the unlocked condition of the connector assembly 144A).

The terminal assembly 304 of the connector assembly 144A is mounted tothe support portion 300 and is electrically connected to the electricalcircuit 28A. The terminal assembly 304 is connectable to the batteryterminal assembly 84 to connect the battery 70 to the circuit 28A.

As shown in FIG. 9, a biasing member or ejector 344 is supported on theclosed end 48A of the receptacle 44A. The ejector 344 is orientedgenerally parallel to the insertion axis 68 and is preferably a springloaded cylinder. The ejector 344 contacts the rear of the battery 70 asthe battery 70 is inserted into the receptacle 44A and exerts a biasingforce on the rear of the battery 70 toward the open end 56 of thereceptacle 44A. As the battery 70 is inserted into the receptacle 44A,the ejector 344 is compressed until the battery 70 is locked to theconnector assembly 144A. When the battery 70 is unlocked from theconnector assembly 144A, the biasing force of the ejector 344 moves thebattery 70 toward the open end 56A to a more accessible position (theejected position).

An alternative construction of a portion of an electrical component 20Bis illustrated in FIG. 11. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-10. Common elements are identifiedby the same reference numbers “B”.

As shown in FIG. 11, a separate locking assembly, such as the lockingassembly 168 or 168A, described above, is not provided. In thisconstruction, the cover 66B is used to lock the battery 70 to theelectrical component 20B.

In this construction, the cover 66B includes the cover biasing member69B, which engages the battery 70 and biases the battery 70 rearwardlyinto the receptacle 44B as the cover 66B is closed. The ejector 344Bcontacts and exerts a forward biasing force on the rear of the battery70. When the latch 67B is engaged, the battery 70 is locked in aposition relative to the housing 24B.

In FIGS. 1-11 and in the above description, a slide-on type power toolbattery 70 is illustrated and described with respect to the electricalcomponent. It should be understood that other battery types, such as,for example, a tower type power tool battery 72 (shown in FIG. 12) or abattery for another piece of electrical equipment (not shown), can beutilized with the electrical component 20.

An alternative construction of a portion of an electrical component 20Cis illustrated in FIG. 12. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-11. Common elements are identifiedby the same reference numbers “C”.

As shown in FIG. 12, the electrical component 20C includes a towersupport portion 348, replacing the slide-on power tool support portion148 and 300 in the above-described constructions, to receive the towerpower tool battery 72. The battery 72 includes a base portion 352, atower portion 356, and a battery terminal assembly 360 and is usablewith a tower power tool (not shown). The support portion 348 is mountedin the receptacle 44C and includes a housing 364 defining a cavity 368and a support portion terminal assembly 372. The cavity 368 has sidewalls 376, an open end 380, and a closed end 384. The cavity 368accommodates the tower portion 356 of the battery 72 to allow the towerportion 356 to insert into the open end 380 of the cavity 368. Thesupport portion terminal 372 is mounted in the cavity 368 and iselectrically connected to the electrical circuit 28C.

The tower power tool battery 72 is inserted into the cavity 368 and issupported by the tower power tool support portion 348. When the battery72 is fully inserted into the cavity 368, the battery terminal assembly360 contacts the support portion terminal 372, electrically connectingthe battery 72 to the electrical circuit 28C.

The support portion 348 may be supported in the receptacle 44 in mannerssimilar to the above-described constructions for the slide-on battery70. In some constructions (similar to that shown in FIGS. 6-8), thesupport portion 348 may be movable in the housing 24C to accommodatedifferent types and sizes of tower batteries, and the support portion348 may be locked in an axial position relative to the housing 24C. Insuch constructions, the support portion 348 may be biased forwardly to,in the unlocked condition, move the battery 72 to a more accessibleposition (the ejected position). In some other constructions (similar tothat shown in FIGS. 9-10 for the slide-on battery 70), the battery 72may be locked to the support portion 348, and an ejector (not shown) maybe provided to bias the battery 72 out of the receptacle 44C to a moreaccessible position (the ejected position).

As shown in FIG. 13, the electrical component 20 also includes a DCoutlet 390 for supplying power to DC electrical equipment, such as, forexample, a cell phone, a cell phone charger, an auxiliary audiocomponent, an automotive power accessory, etc. The power supply portionof the electrical circuit 28 supplies power to the DC outlet 390. The DCoutlet 390 is electrically connected to the battery 70 and, therefore,is operable to electrically connect and supply power from the battery 70to the electrical equipment. The DC outlet 390 is also connectable tothe AC power source through the electrical circuit 28 to connect theelectrical equipment to the AC power source. The electrical circuit 28is protected by a double fuse design having a resettable thermal fuseand a replaceable fuse.

The electrical component 20 also includes an auxiliary plug 392 forconnecting an auxiliary component (not shown), such as, for example, atape player, a CD player or a MP3 player, to the audio circuit portion29. The power amplifier portion of the electrical circuit 28 amplifiesthe input of the auxiliary component. The electrical circuit 28 thusprovides a loop for an auxiliary component in which the power supplyportion powers the auxiliary component and the power amplifier portionreceives and amplifies the input from the auxiliary component.

As shown in FIG. 14, the electrical component 20 also includes anaccessory bag 393 selectively mountable in a rear well portion 394 (seeFIG. 13) of the housing 24. The accessory bag 393 is selectivelydetachable and attachable to the electrical component 20, and items,such as, the DC electrical equipment and supplies, can be stored in theaccessory bag 393. The accessory bag 393 includes openings 396 throughwhich cords pass to connect auxiliary components in the accessory bag393 to the DC outlet 390 and/or to the auxiliary plug 392. The opening396 may be substantially closed (for example, by zippers or VELCRO®strips) during operation to substantially enclose the contents of theaccessory bag 393.

The electrical circuit 28 also includes (see FIG. 15) a display portion398 positioned on the front of the electrical component 20. The displayportion 398 is preferably a backlit LCD display capable of displayingthe status and operating condition of the electrical component 20 and ofthe electrical circuit 28. For example, the display portion 398 displaysthe operating mode of the audio circuit portion 29 (i.e., AM, FM, AUX,etc.). If the audio circuit portion is operating in a radio mode, thedisplay portion 398 displays the current station. The display portion398 may also include a clock or other informational displays.

The electrical component 20 also includes (see FIGS. 1 and 15) a controlportion 400 for controlling the operation and operating mode of theelectrical component 20 and of the electrical circuit 28. The controlportion 400 includes (see FIG. 1) adjustment knobs 402 for adjusting thevolume and for tuning the radio. The control portion 400 also includes(see FIG. 15) control buttons 404 for controlling other operations, suchas pre-set radio station selection, equalization setting, etc.Preferably, the electrical component 20 includes a “PUNCH EQ” featurehaving several pre-set equalization settings. The “PUNCH EQ” button 404is a color lit button using different colors (red, yellow, green)representing the different equalization setting and to indicate thecurrent equalization setting.

Referring to FIG. 17, an alternative construction of the electricalcomponent 20 is illustrated. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-16. The electrical component 20 inthis construction may not include a charging circuit portion to charge abattery 64. A separate battery charger 410 may be used with theelectrical component 20. The charger 410 may be supported on the housing24, in the accessory bag 393 or may be independently mountable in therear well portion 394 of the housing 24 in a manner similar to thesupport of the accessory bag 393. The charger 410 may be mounted on thehousing 24 in any location an in any manner. In the illustratedconstruction, the battery charger 410 includes a charger housing 414providing a battery support portion 416 on which a battery 64 issupportable. A charging circuit (not shown) is supported by the chargerhousing 414 and is connectable to the battery 64 and to a power source(not shown). The charging circuit may be connected to the power sourcethrough an outlet on the electrical component 20 (i.e., the DC outlet390 or an AC outlet (not shown) on the electrical component 20) or onthe power cord for the electrical component 20 or through a power sourceoutlet (i.e., a wall plug). In other constructions (not shown), thebattery charger 410 may be connectable to the power source throughcooperating terminal assemblies (not shown) on the battery charger 410and on the electrical component 20.

In the illustrated construction, the electrical component 20 includesheaded fasteners 418 which are received in openings (not shown) definedin the housing 414 of the battery charger 410 to connect the batterycharger 410 to the electrical component 20. The openings may include awide portion for receiving the head of a fastener 418 and a narrow slotportion into which the fastener 418 slides to prevent the fastener 418from being removed from the opening to thereby prevent the batterycharger 410 from being disconnected from the electrical component 20.The electrical component 20 and separate battery charger 410 provide aconnectable housing assembly.

In some constructions, the charger 410 may be supported in the accessorybag 393, which is then mounted to the housing 24. In otherconstructions, the charger 410 may be slidably mounted to the housing 24by a slot and projection connection (not shown). For example, one of thehousing 24 and the charger 410 includes a slot and the other of thehousing 24 and the charger 410 includes a projection. The slot and theprojection are slidably engaged to mount the charger 410 to the housing.

For example, the charger 410 can be connected to the housing 24 in amanner similar to the manner in which a battery 70 is connected to apower tool, such as a groove and rail connection. In such a groove andrail connection, one of the housing 24 and the charger 410 include agroove, such as the groove 104 on the battery 70 (see FIG. 5), and theother of the housing 24 and the charger 410 include a rail, such as therail 116 of the power tool (see FIG. 5). The groove and rail of thehousing 24 and the charger 410 are engageable to mount the charger 410to the housing 24.

In constructions in which the charger 410 is slidably mounted to thehousing 24, one of the housing 24 or the battery charger 410 may includea locking device (not shown) for selectively locking the charger 410 tothe housing 24. A snap locking device may be used when the charger 410is mounted to the housing 24 in any manner.

The battery charger 410 includes a charger housing 414 providing abattery support portion 416 on which a battery 64 is supportable. Acharging circuit (not shown) is supported by the charger housing 414 andis connectable to the battery 64 and to a power source (not shown). Thecharger 410 may include a power cord (not shown) that is electricallyconnected to the charging circuit and that extends from the chargerhousing 414 and is connectable to the power source through an outlet onthe electrical component 20 (i.e., the DC outlet 390 or an AC outlet(not shown) on the electrical component 20.

In other constructions (not shown), the battery charger 410 may beconnectable to the power source through cooperating terminal assemblies(not shown) on the battery charger 410 and on the electrical component20. For example, the housing 24 and the charger 410 may includecomplementary plug connectors (not shown) that engage each other whenthe charger 410 is connected to the housing 24, thereby electricallyconnecting the battery charging circuit to the power source.

In yet other constructions, the charger 410 may be connected to thepower source by mounting the charger 410 to the housing in a mannersimilar to mounting a battery to the charger 410. In such constructions,the housing 24 and the charger 410 may have a groove and rail typeconnection and include terminals to electrically connect the charger 410to the power source.

The electrical component 20 may accommodate different types of batterychargers and, therefore, be capable of charging different types andsizes of batteries, including slide-on power tool batteries 64 (with thebattery charger 410 and supported on the battery support portion 416),other types of slide-on power tool batteries (not shown, with anothertype of slide-on battery charger (not shown)) and tower power toolbatteries (with a tower battery charger (not shown)) and batteries forother electrical components and/or other electrical equipment (withrespective compatible battery chargers (not shown)).

The electrical component 20 may also accommodate a plurality of batterychargers and, therefore, be capable of charging a plurality ofbatteries. The battery chargers may be different types of batterycharger, thereby allowing various types and sizes of batteries to becharged by the electrical component 20.

Referring to FIG. 17A, another alternative construction of theelectrical component 20 is illustrated. Reference is made to the abovediscussion regarding the structure, operation, and alternatives of theelectrical component 20 illustrated in FIGS. 1-16. The electricalcomponent 20 in this construction may not include a charging circuitwithin the housing 24 to charge a battery 64. A separate batterycharging circuit may be used with the electrical component 20 and may bepositioned along the power cord 31 rather than within the housing 24 ofthe electrical component 20.

In the illustrated construction, the battery charging circuit 28 ishoused within a circuit housing 568 and may be integrally formed withthe power cord 31 or may be selectively connectable to the cord 31 via aplug-type connection (not shown but similar to the wall plug 500) or aquick-lock connection (not shown but similar to the quick-lockconnection 504 discussed above). The battery charging circuit 28 may bepositioned anywhere along the power cord 31, and the circuit housing 568may be connectable to and supportable by the housing 24 of theelectrical component 20 (in a manner similar to the manners discussedabove with respect to the alternative construction illustrated in FIG.17). In other constructions or in other operations, the circuit housing568 may not be connected to the housing 24 of the electrical component20, but may simply be on some other surface, such as, for example, theground, a work bench/table, etc., with the electrical component 20.

In the illustrated construction, the battery charging circuit 28 iselectrically connected to the electrical component 20 via the power cord31 and is electrically connected to a battery 70 positioned within thereceptacle 44 of the electrical component 20 to charge the battery 70.

In some constructions (not shown), a battery support portion (not shown)and a battery terminal (not shown) may be supported by the circuithousing 568 to support a battery(s) 70 and electrically connect thebattery(s) 70 to the charging circuit 28 to charge the battery(s) 70.

In constructions in which the power cord 31 is connected to the housing24 of the electrical component 20 via a plug or a quick-lock connection504 and the battery charging circuit 28 and housing 568 are integralwith the power cord 31, the power cord 31 and the associated batterycharging circuit 28 can be replaced or disconnected from the housing 24,for example in case of power cord 31 and/or battery charging circuit 28damage, for storage purposes, for transportation purposes, forreplacement of the power cord 31 with a different type of power cord,such as, for example, a regular power cord 31 without a battery chargingcircuit positioned along the power cord 31, etc. In other constructionsin which the power cord 31 is connected to the housing 24 and to thebattery charging circuit 28 via respective plug or quick-lockconnections 504, the power cord 31 and the battery charging circuit 28can be replaced or disconnected from each other and/or disconnected fromthe housing 24, for example, in case of power cord 31 and/or batterycharging circuit 28 damage, for storage purposes, for transportationpurposes, etc.

Referring to FIG. 17B, an alternative construction of the electricalcomponent 20 is illustrated. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-17A. The electrical component 20 inthis construction may not include a charging circuit within the housing24 to charge a battery 64. A separate battery charging circuit 28 may beused with the electrical component 20 and may be positioned at the powersource outlet or wall plug 500. The battery charging circuit 28 may beintegrally formed with the wall plug 500 and housed within the wall plughousing 570 (see FIGS. 13 and 17A and 17B) or may be separately housedin a circuit housing (not shown) and selectively connectable to the wallplug 500 via a plug-type connection, a quick-lock connection 504,fasteners, or other manners of connection.

In the illustrated construction, the battery charging circuit 28 iselectrically connected to the electrical component 20 via the power cord31 and is electrically connected to a battery 70 positioned within thereceptacle 44 of the electrical component 20 to charge the battery 70.

In other constructions (not shown), a battery support portion (notshown) and a battery terminal (not shown) may be integral with wall plughousing 570 and positioned at the wall plug 500 with the chargingcircuit 28 to support a battery(s) 70 and electrically connect thebattery(s) 70 to the charging circuit 28 to charge the battery(s) 70.

The power cord 31 may be connected to the housing 24 of the electricalcomponent 20 by either a quick-lock connection 504, as illustrated. Incase of power cord 31 damage, charging circuit damage or wall plug 500damage, etc., any number of the power cord 31, charging circuit 28 andthe wall plug 500 can be replaced. Any number of the power cord 31,charging circuit 28 and wall plug 500 can be disconnected from thehousing 24 for storage purposes, transportation purposes, etc. The powercord 31 may also be removed for storage and transportation purposes andreconnected after storage and transportation or may be replaced with adifferent type of power cord 31, such as, for example a regular powercord 31 that does not have a battery charging circuit positioned withthe wall plug 500.

In other constructions, the power cord 31 may be hard wired with theelectrical component 20.

FIGS. 18-20 illustrate the connection of the handle portion 40 to thebase portion 32 and to the main portion 36 of the housing 24. In theillustrated construction, the handle portion 40 is connected to both thebase portion 32 and the main portion 36 at two locations by baseconnecting assemblies 422 and main connecting assemblies 426,respectively. The base connecting assemblies 422 are similar to oneanother, and the main connecting assemblies 426 are similar to eachother. Therefore, only one base connecting assembly 422 and one mainconnecting assembly 426 will be described in detail.

As shown in FIGS. 18-19, the base portion 32 defines a base aperture430, and the base connecting assembly 422 includes an upper insert 434and a lower insert 438 received in the base aperture 430. A threadedmember 442 connects the lower insert 438 to one end of the handleportion 40 and to the upper insert 434 so that the handle portion 40 isflexibly mounted to the base portion 32.

As shown in FIGS. 18 and 20, the main connecting assembly 426 includes aflexible member 446 surrounding a tube 450. Fasteners 454 and 458connect the handle portion 40 and the main portion 36, respectively, tothe flexible member 446 and the tube 450 so that the handle portion 40is flexibly mounted to the main portion 36. The main connecting assembly426 absorbs shocks to the upper portion of the handle portion 40.

As discussed above and with reference to FIGS. 21-27, the electricalcomponent 20 may be connected to an AC power source via the power cord31. The power cord 31 includes a wall plug 500 at one end for engaging acomplementary electrical outlet (not shown) and is connected to thehousing 24 of the electrical component 20 at the other end. In theillustrated construction, the power cord 31 is connected to the housing24 and to the electrical circuit 28 with a quick-lock connection 504. Inother embodiments, the power cord 31 may be hard-wired to the electricalcomponent 20 and electrically connected to the electrical circuit 28.

With reference to FIGS. 21-25, the electrical component 20 defines asupport portion 508 that supports a circuit electrical connector 512.The support portion 508 supports the power cord 31, when connected tothe housing 24. The support portion 508 defines at least one and,preferably, more than one housing thread 516.

The power cord 31 includes (see FIG. 24) a cord electrical connectorhousing 520 supporting a cord electrical connector 524 and a wall plug500 connected by a conductive wire 528 to the cord electrical connector524. The cord electrical connector 524 is electrically connectable tothe circuit electrical connector 512, and the plug 500 is connectable toa power source, such as, for example, an electrical outlet, toelectrically connect the electrical circuit 28 to the power source.

The power cord 31 is removably connectable to the housing 24 and alsoincludes a mounting portion 532 supporting and surrounding the cordelectrical connector housing 520 and the cord electrical connector 524.The mounting portion 532 is rotatable relative to the cord electricalconnector housing 520 and relative to the cord electrical connector 524.The mounting portion 532 defines at least one and, preferably, more thanone cord thread 536. The cord threads 536 are complementary to andengage with the housing threads 516.

The electrical component 20 and the power cord 31 include a lockingassembly for positively locking the power cord 31 to the housing 24 ofthe electrical component 20. The locking assembly includes a firstlocking member or slider 540. In one construction (see FIGS. 23 and 25),the slider 540 is supported on the support portion 508. The slider 540includes (see FIGS. 23 and 25) a locking protrusion 544. The slider 540is slidable along an axis generally parallel to the axis of the supportportion 508 between a locking position (shown in solid lines in FIG. 23)and an unlocked position (shown in phantom lines in FIG. 23). A spring(not shown) biases the slider 540 toward the locking position (in adirection indicated by arrow A).

The locking assembly also includes a second locking member or lockingrecess 548. In the construction illustrated in FIGS. 21-25, the mountingportion 532 also defines the locking recess 548. The locking recess 548is engageable by the locking protrusion 544 of the slider 540 to preventrotation of the mounting portion 532 relative to the support portion508. The slider 540 and the recess 548 thus provide the locking assemblyfor the power cord 31 and the electrical component 20.

It should be understood that, in other constructions (not shown), aslider (similar to the slider 540) may be supported on the mountingportion 532, and a locking recess (similar to the locking recess 548)may be defined by the support portion 508. In such a construction, theslider on the mounting portion 532 engages the locking recess defined bythe support portion 508 to positively lock the power cord 31 to thehousing 24.

It should also be understood that, in other constructions (not shown), aslider (similar to the slider 540) may be supported on the housing 24,and a locking recess (similar to the locking recess 548) may be definedby the power cord 31. In such a construction, the slider on the housing24 engages the locking recess defined by the power cord 31 to positivelylock the power cord 31 to the housing 24.

As shown in FIG. 23, indicator members or arrows 552 and 556 are formedon the support portion 508 and the mounting portion 532, respectively,to provide an indication to the operator as to the locked condition ofthe power cord 31. When the arrow 552 formed on the support portion 508is aligned with the arrow 556 formed on the mounting portion 532, thepower cord 31 is in a locked condition (the cord threads 536 are engagedwith the housing threads 516). As shown in FIG. 22, a directional arrow560 formed on the mounting portion 532 indicates the direction ofrotation of the mounting portion 532 to the unlocked condition.

To mount the power cord 31, the slider 540 is moved to the unlockedposition (in the direction opposite to arrow A in FIG. 23). The mountingportion 532 is inserted into the support portion 508, and the cordelectrical connector 524 is connected to the circuit electricalconnector 512. The mounting portion 532 is then rotated in the directionopposite to the arrow 560 (in FIG. 22) relative to the support portion508 and relative to the electrical connectors 508 and 512 so that thethreads 516 and 536 engage. When the arrows 552 and 556 are aligned, thepower cord 31 has been rotated to the locked condition. The slider 540is then released and moves under the force of the biasing spring to thelocked position (in the direction arrow A in FIG. 23). The lockingprotrusion 544 engages in the locking recess 548 to prevent the mountingportion 532 from rotating relative to the support portion 508 and toprevent the threads 516 and 536 from being disengaged. In this manner,the power cord 31 is positively locked to the housing 24.

In the illustrated construction, the slider 540 is held in the unlockedposition by an operator until the power cord 31 has been rotated to thelocked condition. The operator then releases the slider 540, allowingthe slider 540 to move to the locking position.

In other constructions (not shown), the insertion of the mountingportion 532 into the support portion moves the slider 540 to theunlocked position. The mounting portion 532 cooperates with the slider540 to move the slider 540 to the unlocked position. In suchconstructions, once the power cord 31 is rotated to the lockedcondition, the slider 504 is allowed to move to the locking position.

To remove the power cord 31 from the housing 24, the mounting procedureis simply reversed. The slider 540 is moved to the unlocked position (inthe direction opposite to arrow A in FIG. 23) so that the lockingprotrusion 544 is removed from the locking recess 548. The mountingportion 532 is rotated in the direction of the arrow 560 (in FIG. 22)relative to the support portion 508 so that the threads 516 and 536disengage. The mounting portion 532 is then removed from the supportportion 508, and the cord electrical connector 524 is disconnected fromthe circuit electrical connector 512. The removability of the power cord31 facilitates replacement of a damaged cord or replacement of the powercord 31 with a different type of cord, such as, for example a batterycharging power cord (discussed in greater detail below). The power cord31 may also be removed for storage or transportation purposes andreconnected to the electrical component 20 after storage ortransportation is complete. Also, the positive locking arrangementbetween the power cord 31 and the housing 24 ensures that the power cord31 does not disengage from the housing 24, for example, if theelectrical component 20 is hung by the power cord 31 (e.g., an operatorholds the power cord 31 while lowering or lifting the electricalcomponent 20).

FIGS. 26 and 27 illustrate an alternative construction of a power cord31D embodying the invention. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-25. Common elements are identifiedby the same reference numbers “D”.

In the alternative construction, the locking assembly includes a firstlocking member or slider 540D supported on the mounting portion 532D ofthe power cord 31D. The slider 540D includes (see FIG. 27) a lockingprotrusion 544D. The slider 540D is slidable along an axis generallyparallel to the axis of the mounting portion 532D between a lockingposition (shown in solid lines in FIG. 27) and an unlocked position(shown in phantom lines in FIG. 27). A spring (not shown) biases theslider 540D toward the locking position (in a direction indicated byarrow B).

The locking assembly also includes a second locking member or lockingrecess 548D formed on the cord electrical connector housing 520D of thepower cord 31D. The locking recess 548D is engageable by the lockingprotrusion 544D of the slider 540D to prevent rotation of the mountingportion 532D relative to the cord electrical connector housing 520D andrelative the support portion 508D (when the power cord 31D is connectedto the housing 24). The slider 540D and the recess 548D thus provide thelocking assembly for the power cord 31D and the electrical component 20.

To mount the power cord 31D, the slider 540D is moved to the unlockedposition (in the direction opposite to arrow B in FIG. 27). The mountingportion 532D is inserted into the support portion (not shown but similarto the circuit electrical connector 508), and the cord electricalconnector 524D is connected to the circuit electrical connector (notshown but similar to the circuit electrical connector 512). The mountingportion 532D is then rotated in the direction opposite to the arrow 560D(see FIG. 26) relative to the support portion and relative to thecircuit electrical connector and the cord electrical connector 524D sothat the housing threads (not shown but similar to the housing threads516) and the cord threads 536D engage. When the arrows of the indicator(not shown) are aligned, the power cord 31D has been rotated to thelocked condition. The slider 540D is then released and moves under theforce of the biasing spring to the locking position (in the directionarrow B in FIG. 27). The locking protrusion 544D engages in the lockingrecess 548D to prevent the mounting portion 532D from rotating relativeto cord electrical connector housing 520D and relative to the supportportion and to prevent the cord threads 536D and the housing threadsfrom being disengaged. In this manner, the power cord 31D is positivelylocked to the housing 24.

In the construction illustrated in FIGS. 26 and 27, the slider 540D isheld in the unlocked position by engagement with a ridge 564 formed onthe cord electrical connector housing 520D until the power cord 31D hasbeen rotated to the locked condition. The slider 540D is then disengagedfrom the ridge 564, allowing the slider 540D to move to the lockingposition.

To remove the power cord 31D from the housing 24, the mounting procedureis simply reversed. The slider 540D is moved to the unlocked position(in the direction opposite to arrow B in FIG. 27) so that the lockingprotrusion 544D is removed from the locking recess 548. The mountingportion 532 is rotated in the direction of the arrow 560D (in FIG. 26)relative to the cord electrical connector housing 520D and relative tothe support portion so that the housing threads and the cord threads536D disengage. The mounting portion 532D is then removed from thesupport portion, and the cord electrical connector 524D is disconnectedfrom the circuit electrical connector. The power cord 31D or a new powercord (not shown but similar to the power cord 31D) may then be connectedto the electrical component 20 in the manner described above.

The invention thus provides, in some aspects, a power cord 31 or 31Dwhich may be easily removed and replaced for storage purposes, fortransportation purposes or if the power cord 31 or 31D is damaged. Also,in some aspects, the invention provides a power cord 31 or 31D which ispositively locked to the housing 24 to ensure electrical and physicalconnection of the power cord 31 or 31D and the electrical component 20.

It should be understood that, in other constructions (not shown), thefirst locking member 540 or 540D may engage the locking recess 548 or548D in a direction other than parallel to the axis, such as, forexample, in a radial direction. Further, the first locking member 540 or540D may be supported for movement other than sliding movement, such as,for example, pivotal movement.

With reference to FIGS. 28 and 29, the electrical component 20 includesa MP3 player 572 that is supported by the housing 24. The MP3 player 572can be a variety of MP3 players available for purchase from companies,such as, for example Apple Computer Inc., Celera, JVC Americas Corp.,Koss, Panasonic, Philips, RCA, Rio, Sharper Image, Sony, etc.

With particular reference to FIG. 28, the MP3 player 572 is externallyconnected to the housing 24. The MP3 player 572 may be either rigidlyconnected to and non-removable from the housing 24 or may be selectivelyremovable from the housing 24.

With particular reference to FIG. 29, the MP3 player 572 may be encasedwithin the housing 24. In such constructions, the MP3 player 572 may beeither rigidly connected to and non-removable from the housing or may beselectively removable from the housing. In constructions in which theMP3 player is encased within the housing 24, a surface of the MP3 player572 may be flush with, slightly projecting outwardly from the externalsurface of the housing 24 or recessed below the external surface of thehousing 24.

In some constructions (not shown), the MP3 player 572 may be coveredwith a cover (not shown) to protect the MP3 player 572 and/or to lockthe MP3 player to the housing 24. In some constructions, the cover istransparent to allow an operator to view the MP3 player through thecover. In other constructions, the cover is not transparent and the MP3player 572 is not viewable through the cover.

The MP3 player 572 includes a MP3 circuit (not shown) operable to playMP3 audio signals and a plurality of control buttons 576 for controllingthe operation of the MP3 player 572, such as volume control, trackselection, play mode (i.e., random or continuous play), etc. The MP3circuit is electrically connected to the power cord 31 and is therebyelectrically connected to the power source to power the MP3 circuit.

In some constructions, the MP3 player 572 may be electrically connectedto both the battery 70 and to the power source. In such constructions,the MP3 player 572 may be powered by either of the battery 70 and thepower source. Preferably, the MP3 player 572 will be powered primarilyby the power source in such constructions. However, if the power cord 31is unplugged from the power source, the MP3 player 572 will be poweredby the battery 70. In other constructions, the MP3 player 572 may bepowered solely by the battery 70.

The MP3 player 572 also includes a display portion 580 that is operableto display various information to an operator, such as, for example,volume level, current track selection and/or track title, number oftotal tracks, elapsed play time of current track, remaining play timefor current track, selected play mode (i.e., random or continuous),messages, etc. The display portion 580 may be various types of displays,including analog, digital, etc., for electrical components. In theillustrated construction, the display portion 580 is a backlit LCDdisplay.

The MP3 player 572 further includes internal memory (not shown).Additional memory can be added to the MP3 player 572 by providing aseparate memory device (not shown), such as, for example, a memorystick, memory chip, etc., for the MP3 player 572. For example, thememory device is selectively insertable into and removable from the MP3player 572.

Referring back to FIG. 29, in the illustrated construction, theelectrical component 20 includes a memory device port 596 for receivingseparate memory devices. The memory device port 596 is preferably shapedto accommodate one or more shapes of memory devices. For example, thememory device port 596 may have a rectangular shape to accommodate arectangularly-shaped memory chip. The electrical component 20 may alsoinclude a port cover (not shown) to cover the port 596. The cover maycover the port 596 when the port 596 is unused or when the port 596 isboth used and unused.

It should be understood that the electrical component 20 can be anycombination of a radio, a battery charger and a MP3 player and caninclude any combination of an audio circuit, a battery charging circuitand a MP3 circuit. For example, the electrical component 20 can be aradio, a battery charger, a MP3 player, a radio/charger, a radio/MP3player, a MP3 player/charger or a radio/charger/MP3 player and caninclude an audio circuit only, a battery charging circuit only, a MP3circuit only, an audio and a battery charging circuit, an audio circuitand a MP3 circuit, a MP3 circuit and a battery charging circuit or anaudio circuit, battery charging circuit and a MP3 circuit, respectively.

An alternative construction of an electrical component 20E isillustrated in FIGS. 30-33. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-29. Common elements are identifiedby the same reference numbers “E”.

Referring to FIGS. 30-33, the electrical component 20E includes aplurality of power cells 584. The power cells 584 may be electricallyconnected to a power source via the power cord 31E and may be chargedwhen the power cord 31E is plugged into the power source. In theillustrated construction, the power cells 584 are positioned within thehousing 24E of the electrical component 20E (see FIG. 30).

In some constructions, the power cells 584 can be supported externallyof the housing 24E. In constructions in which the power cells 584 aresupported externally of the housing 24E, the power cells 584 may behoused within a separate power cell housing 588 (see FIGS. 32 and 33) ormay be housed within an extension 592 (see FIG. 31) of the housing 24Eor may not be housed in anything. Also, in such embodiments where thepower cells 584 are supported externally of the housing 24E, the powercells 584 may be connected to the housing 24E, such as, for example, byfasteners, Velcro, etc., may be supported on some other surface, suchas, for example the ground, a table, etc., or may be positioned alongand in series with the power cord 31E (see FIG. 33). The electricalcomponent 20E may also include a charging circuit (not shown but similarto charging circuit 28) in electrical communication with the power cells584 and/or the battery 70.

In addition, the power cells 584 are electrically connected to an audiocircuit (not shown) in order to produce audio signals. In someconstructions, the audio circuit is only powered by the power cells 584when the power cord 31E is both plugged into and not plugged into thepower source.

In other constructions, the audio circuit can be powered by either thepower cells 584 or by the power source. For example, the audio circuitcan be powered by either or both the power cells 584 and the powersource when the power cord 31E is plugged into the power source. Whenthe power cord 31E is not plugged into the power source, the audiocircuit and/or the MP3 circuit is powered by the power cells 584.

It should be understood that the power source (when the power cord 31Eis plugged into the power source) can both charge a battery 70positioned within the receptacle 44 and power the audio circuit. In sucha case, the power source can also charge the power cells 584. It shouldalso be understood that the power source can charge the power cells 584and the battery 70 positioned within the receptacle 44, and the powercells 584 can power the audio circuit.

FIGS. 34-48 illustrate an alternative construction of an electricalcomponent 20F embodying the invention. Reference is made to the abovediscussion regarding the structure, operation, and alternatives of theelectrical component 20 illustrated in FIGS. 1-33. Common elements areidentified by the same reference numbers “F”.

As shown in FIGS. 34-40, the housing 24F generally includes a centralportion 600, a right portion 604, and a left portion 608. In theillustrated construction, the central portion 600, right portion 604,and the left portion 608 are designed to have impact absorbingcharacteristics which protect the electrical component 20F from impactsat a jobsite, such as from falling from a height or having anotherobject impact the electrical component 20F, which might normally damagethe elements of the electrical component 20, such as, for example, theelements of the electrical circuit 28F, and/or create an electricalhazard in the electrical component 20F. For example, the housing 24F maybe formed of energy/impact absorbing materials, such as, for example,high-density polyethylene (HDPE), and/or formed with energy/impactabsorbing structures, such as, for example, bars, base edges, bumpers,bushings, ribs, honeycombs, energy-absorbing shapes, etc.

With continued reference to FIGS. 34-40, a plurality of support members612 extend downwardly from the bottom surface of the electricalcomponent 20F. The support members 612 provide support and sturdiness tothe electrical component 20F when the electrical component 20F ispositioned on a work surface. The central portion 600 includes a batteryconnection assembly 616, a battery charger 37, a control portion 620, ahandle 40F, and a central frame 624 extending outward from the outerbounds of the battery connection assembly 616, the battery charger 37,the control portion 620 and the handle 40F to protect those componentsfrom impacts and to substantially prevent damage thereto from suchimpacts.

The right portion 604 and the left portion 608 are substantially mirrorimages of each other and include similar components. The right portion604 and the left portion 608 each include a speaker 628 and a speakerframe 632 surrounding the speaker 628 to protect the speaker 628 fromimpacts and prevent damage to the speaker 628 from such impacts.

With reference to FIGS. 41-42 and 45, in the illustrated construction,the battery connection assembly 616 defines a receptacle 44F having aclosed end 48F, defined by a bumper 52F (discussed below), an open end56F, and side walls 60F extending from the closed end 48F to the openend 56F. A battery 64F is inserted into the receptacle 44F along aninsertion axis 68F. The battery 64F is electrically connected to theelectrical circuit 28F to, in the illustrated construction, selectivelyprovide power to the electrical circuit 28F. In some constructions, thebattery 64F can selectively provide power to the electrical circuit andbe charged by the charging circuit portion 30 of the electrical circuit28.

With reference to FIGS. 34-45, the housing 24F includes a cover 66Fpivotally connected to the central frame 624 for selectively closing theopen end 56F of the receptacle 44F. A latching member 67F is selectivelylockable to a portion of the central frame 624 (see FIGS. 34-40) to lockthe cover 66F in a closed position (shown in FIGS. 34-40). In someconstructions, a cover biasing member (not shown) is mounted on theinterior surface of the cover 66F. When the cover 66F is closed, thebiasing member engages and biases the battery 64F into the receptacle44F to maintain proper electrical connection, as described below in moredetail, during normal operations or during and after an impactcondition. In the illustrated construction, the battery is a slide-onpower tool battery 70 operable to power a power tool 71, such as, forexample, a drill, a circular saw, a reciprocating saw, etc.

As shown in FIGS. 41 and 42, the central frame 624 supports anelectrical connector assembly 144F positioned in the receptacle 44F. Theconnector assembly 144F includes a support portion 148F, a body portion152F, a terminal assembly 156F, biasing members 160F, the bumper 52F,and a locking assembly 168F. In the illustrated construction, thesupport portion 148F and the terminal assembly 156F move within thereceptacle 44F relative to the housing 24F, in a direction parallel tothe insertion axis 68F, upon the insertion and ejection of the battery70 into and out of the receptacle 44F, respectively. In part, thismovement accommodates batteries of different sizes.

Referring to FIGS. 34-40 and 47, the battery charger 37 is supported bythe central frame 624 and is selectively removable from the centralframe 624. The battery charger 37 includes a charger housing 636 and aplurality of elongated projections 640 (see FIG. 47) extending fromsides of the charger housing 636. The projections 640 are receivable ingrooves 644 (see FIG. 47) defined in interior sides of the central frame624. Any number of grooves 644 can be defined in the interior sides ofthe central frame 624 to provide the necessary engagement between thebattery charger 37 and the central frame 624 and/or to provide aplurality of positions for supporting the battery charger 37 within thecentral frame 624.

In some constructions, the charger housing 636 defines grooves in sidesthereof and a plurality of elongated projections extend from interiorsides of the central frame 624, and the grooves and elongatedprojections are engageable to support the battery charger 37 within thecentral frame 624. In such constructions, the interior sides of thecentral frame 624 can include any number of projections to provide thenecessary engagement between the battery charger 37 and the centralframe 624 and/or to provide a plurality of positions for supporting thebattery charger 37 within the central frame 624. It should be understoodthat the battery charger 37 can be supported by the central frame 624 ina variety of manners other than the described projection/grooveengagement, such as, for example a ratchet-type engagement, a fastenerengagement, integrally forming the battery charger with the centralframe, etc.

In the illustrated construction, the battery charger 37 is movablebetween a locked condition, in which the battery charger 37 is insertedto its fullest extent within the central frame 624 and prevented fromsliding forward, and an unlocked condition, in which the battery charger37 is free to move relative to the central frame 624. The batterycharger 37 can be locked to the central frame 624 in a variety ofmanners. For example, the projections 640 and grooves 644 and/or theside surfaces of the battery charger 37 and the central frame 624 may beappropriately sized to frictionally engage each other and to preventmovement relative to each other except when under a force, such as, forexample an operator applying force to the battery charger 37 by pullingor pushing the battery charger 37.

Also for example, a positive locking arrangement, such as a separatelocking member (not shown), can be provided between the battery charger37 and central frame 624. Such a locking member can include aselectively retractable element that is connected to one of the batterycharger 37 and the central frame 624 and that is engageable with anotherelement, such as, for example, a projection or a recess, connected tothe other of the battery charger 37 and the central frame 624. Theretractable element can be retracted by a manipulateable leverengageable by an operator.

With particular reference to FIGS. 44 and 45, the battery charger 37includes an electrical connector assembly 648 for supporting a batteryand for electrically connecting the battery to the charging circuitportion 30F. The connector assembly 648 can have a variety of shapes andconfigurations and can be configured to accommodate a variety of batterysizes and shapes. In the illustrated construction, the connectorassembly 648 is similar to the electrical connector assembly 144F shownin FIGS. 6-8 as discussed above. Reference is made to the abovediscussion regarding the structure, operation, and alternatives of theelectrical connector assembly 144F shown in FIGS. 6-8.

In some constructions, the connector assembly 648 is similar to theelectrical connector 144A shown in FIGS. 9 and 10. Reference is made tothe above discussion regarding the structure, operation, andalternatives of the electrical connector assembly 144A shown in FIGS. 9and 10.

It should be understood that, in some constructions, the battery may belocked in a position relative to the electrical connector assembly 648,and, in such constructions, the electrical connector assembly 648includes an actuator 652 (similar to the actuators 236, 292 of theelectrical connector assemblies 144, 144A) for unlocking the batteryfrom the electrical connector assembly. The actuator 652 can operate inmanners similar to the actuators 236, 292 or can operate in mannersdifferent than the actuators 236, 292.

It should also be understood that the electrical connector assembly 648,whether it is similar to electrical connector assembly 144, electricalconnector assembly 144A, or some other electrical connector assembly,can include a variety of support portion types for supporting a varietyof battery types. For example, the electrical connector assembly 648 caninclude support portions 148, 300, 348 or other battery support portionsranging in a variety of sizes, shapes and configurations for supportingcomplementary-shaped batteries.

Referring to FIGS. 46 and 47, the battery charger 37 further includes acircuit connector assembly 656 for electrically connecting the chargingcircuit portion 30 of the electrical circuit 28F of the electricalcomponent 20F with the battery charger 37 and, therefore, connecting thecharging circuit portion 30 to the battery 70. In the illustratedconstruction, the circuit connector assembly 656 includes a batterycharger terminal assembly 660, a battery charger support portion 664,and locking members or locking tabs 668 (one shown). The battery chargersupport portion 664 has a generally C-shaped cross-section provided bygrooves 672 and rails 676 which extend parallel to a battery chargerinsertion axis (see FIG. 46). Locking tabs 668 are supported in theC-shaped support portion 664 and are movable perpendicular to thebattery charger insertion axis 680.

With particular reference to FIG. 46, the electrical component 20Fincludes a housing electrical connector assembly 684 for engaging thecircuit connector assembly 656 and for electrically connecting thebattery charger 37 to the charging circuit portion 30. In theillustrated construction, the housing electrical connector assembly 656includes a generally T-shaped housing support portion 688 and a housingterminal assembly. The support portion 664 of the battery charger 37 iscomplementary to the support portion 688 of the electrical component20F, and, therefore, the complementary components physically andelectrically connect the battery charger 37 to the electrical component20F. The locking tabs 668 engage in recesses (not shown) on the housingsupport portion 688 to provide a battery charger locking assemblybetween the battery charger 37 and the electrical component 20F.

It should be understood that, in other constructions (not shown), thebattery charger 37 may have a different type of slide-on circuitconnector assembly 656, such as, for example, the circuit connectorassembly 656 having a T-shaped cross-section. In such constructions, thehousing electrical connector assembly 684 would have a complementaryC-shaped cross-section support portion.

It should also be understood that, in other constructions (not shown),the battery charger 37 may have a circuit connector assembly 656 shapedsimilarly to a plug and socket type connection or a projection andreceptacle type connection. In such constructions, one of the circuitconnector assembly 656 and the housing electrical connector assembly 684have a socket or receptacle and the other of the circuit connectorassembly 656 and the housing electrical connector assembly 684 has aplug or projection insertable into the socket or receptacle toelectrically connect the battery charger 37 to the charging circuitportion 30.

It should further be understood that the circuit connector assembly 656and the housing electrical connector assembly 684 can have a variety ofconfigurations as long as the configurations of the circuit connectorassembly 656 and the housing electrical connector assembly 684 arecomplementary and enable electrical connection between the batterycharger 37 and the electrical circuit 28.

It should be understood that, in other constructions (not shown), thebattery charger 37 may include a power cord and plug which isconnectable to a power source, such as through an outlet on theelectrical component 20F, a pass-through plug on the power cord for theelectrical component 20F. It should be understood that the batterycharger 37 may be configured to operated and to charge a battery whendisconnected and independent from the electrical component 20F.

It should also be understood that battery charger 37 is operable tosupport and charge batteries of varying lengths, sizes, and voltages. Inthe illustrated construction and with reference to FIG. 5, the slide-onbattery 70 has a first dimension, such as an axial length, and anotherslide-on battery (shown in phantom in FIG. 5) has a second dimension,such as a second axial length, which is different than that of the firstslide-on battery 70. The battery charger 37 is operable to receive andsupport both batteries and a variety of other batteries.

In addition, it should be understood that the battery charger 37 canreceive and the electrical component 20F is usable with batteries havingdifferent battery chemistries (i.e., Lithium-based chemistries (Li,Li-ion, etc.), Nickel Metal Hydride (NiMH), Nickel Cadmium (NiCd),etc.). The electrical circuit 28F and the charging circuit portion 30may include identification circuitry and structure necessary to identifythe chemistry of the battery 70 to ensure proper charging and operationof the battery 70.

Further, it should be understood that in some constructions theelectrical component 20F can receive a variety of different batterychargers 37 rather than a single battery charger. In such constructions,a broken or otherwise inoperable battery charger can be replaced withanother battery charger so that the electrical component 20F is not leftwithout its battery charging capability when the original batterycharger is inoperable. Also, a battery charger having a differentconfiguration can be connected to the electrical component 20 toaccommodate batteries having different configurations.

Further, it should be understood that in some constructions theelectrical component 20F can include a plurality of battery chargers forcharging a plurality of batteries simultaneously. In such constructions,the housing 24F is configured to enable selective connection of theplurality of battery chargers thereto.

It should be understood that the electrical component 20F may beconfigured to receive, in place of the battery charger 37, a batterycharger for another type of equipment, such as, for example, a cellphone.

Referring to FIGS. 34-40 and 48, the control portion 620 of theelectrical component 20F controls the operation and operating mode(s) ofthe electrical component 20F and of the electrical circuit 28F. Forexample, the control portion 620 can control a radio mode, batterycharging mode, a MP3 mode, a clock mode, etc. The control portion 620includes adjustment knobs 402F for adjusting the volume and for tuningthe radio. The control portion 620 also includes control buttons 404Ffor controlling other operations, such as pre-set radio stationselection, equalization setting, etc. Preferably, the electricalcomponent 20F includes a “PUNCH EQ” feature having several pre-setequalization settings. The “PUNCH EQ” button 404F is a color lit buttonusing different colors (red, yellow, green) representing the differentequalization setting and to indicate the current equalization setting.

The control portion 620 further includes a display portion 398Fpositioned on the front of the control portion 620. In the illustratedconstruction, the display portion 398F is a backlit LCD display.However, the display portion can be any appropriate type of display. Thedisplay portion is capable of displaying the status and operatingcondition of the electrical component 20F and of the electrical circuit28F. For example, the display portion 398F displays the operating modeof the audio circuit portion 29F (i.e., AM, FM, AUX, MP3, etc.). If theaudio circuit portion is operating in a radio mode, the display portion398F displays the current station. If the charging circuit portion ischarging a battery, the display portion 398F displays a charging symbol,such as, for example, a lightning bolt, the letters “CHRG”, etc. If theaudio circuit is operating a MP3 mode, the display portion 398Fdisplays, for example, volume level, the current track selection and/ortrack title, elapsed time of current track, time remaining in currenttrack, number of total tracks, play mode (i.e., random or continuousplay), remaining memory, occupied memory, etc. The display portion 398Fmay also include a clock or other informational displays.

With particular reference to FIG. 48, the control portion 620 may beselectively connectable to the central frame 624 of the housing 24F. Inthe illustrated construction, the control portion 620 includes aplurality of elongated projections 696 extending from sides of thecontrol portion 620 that are receivable in the grooves 644 defined inthe interior sides of the central frame 624. Reference is made to theabove discussion regarding the structure, operation, and alternatives ofthe connectability of the battery charger 37 to the central frame 624.Connectability of the control portion 620 to the central frame 624 issimilar to the structure, operation, and alternatives of the batterycharger.

It should be understood that the battery charger 37 and the controlportion 620 can be oriented differently with respect to each otherwithin the central frame 624. For example, the battery charger 37 can bepositioned above the control portion 620.

It should also be understood that the battery charger 37 and the controlportion 620 are operable independently of each other, and, accordingly,the battery charger 37 and the control portion 620 can operate if theother is disconnected from the electrical component 20F.

It should be understood that, in some constructions, another electricaldevice, such as, for example, another audio component, may besubstituted for the battery charger 37. It should also be understoodthat, in some constructions, another electrical device, such as, forexample, another audio component, another control portion, anotherbattery charger, may be substituted for the control portion 620.

An alternative construction of an electrical component 20G isillustrated in FIG. 49. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-48. Common elements are identifiedby the same reference numbers “G”.

The electrical component 20G in this construction includes a selectivelyconnectable battery charger 37G having a different configuration thanthe battery charger 37 of the electrical component 20F illustrated inFIGS. 34-48. The battery charger 37G in this construction is relativelythinner than the battery charger 37 of the electrical component 20Fillustrated in FIGS. 34-48, however, this battery charger 37G hassimilar operations and alternatives to the battery charger 37 of theelectrical component 20F illustrated in FIGS. 34-48. The electricalcomponent 20G includes a cover plate 700 selectively connectable to thecentral frame 624G of the housing to cover the space occupiable by thebattery charger 37F. The cover plate 700 can be connected to the centralframe 624G when the battery charger 37G is both connected to anddisconnected from the central frame 624G in order to cover the batteryand the battery charger 37G or to cover the void left when the batterycharger 37G is not connected, respectively.

It should be understood that the cover plate 700 can be used with any ofthe constructions of the electrical component 20 illustrated anddescribed herein (both above and below) that include a space occupiableby a selectively connectable battery charger 37.

An alternative construction of an electrical component 20H isillustrated in FIGS. 50 and 51. Reference is made to the abovediscussion regarding the structure, operation, and alternatives of theelectrical component 20 illustrated in FIGS. 1-49. Common elements areidentified by the same reference numbers “H”.

The electrical component 20H includes a base 704, a housing 24H, and ahandle 40H. The base 704 and handle 40H are designed to have impactabsorbing characteristics which protect the electrical component 20Hfrom impacts at a jobsite, such as from falling from a height or havinganother object impact the electrical component 20H, which might normallydamage the elements of the electrical component 20H, such as, forexample, the elements of the electrical circuit 28H, and/or create anelectrical hazard in the electrical component 20H. For example, the base704 or the handle 40H may be formed of energy/impact absorbingmaterials, such as, for example, high-density polyethylene (HDPE),and/or formed with energy/impact absorbing structures, such as, forexample, bars, base edges, bumpers, bushings, ribs, honeycombs,energy-absorbing shapes, etc.

With particular reference to FIG. 51, a charger receptacle 708 isdefined in the rear of the housing 24H and the base 704 for receiving abattery charger 37H. The battery charger 37H is selectively connectableto the electrical component 20H. In the illustrated construction, arecess 712 is defined in opposing sides of the battery charger 37H and acomplementary projection 716 extends from each side of the chargerreceptacle 708. The battery charger 37H is inserted into the chargerreceptacle 708 by aligning the projections 716 with the recesses 712,inserting the projections 716 into the recess 712, and sliding thebattery charger 37H along the projections 716. The battery charger 37His inserted into the charger receptacle 708 until a rear surface of thebattery charger 37H is substantially flush with the rear surface of thehousing 24H and the base 704. One or both of the electrical component20H and the battery charger 37H may include a locking member (not shown)for positively locking the battery charger 37H within the chargerreceptacle 708.

In the illustrated construction, the battery charger 37H includes abattery support portion 148H for supporting slide-on type power toolbatteries. The support portion 148H has similar construction, operation,and alternatives to the slide-on type support portion 148 of theelectrical component 20 illustrated in FIGS. 1-49.

It should be understood that the battery charger 37H can include batterysupport portions operable for supporting power tool batteries, such as,for example, tower power tool batteries, etc., other than slide-on typepower tool batteries and have similar construction, operation, andalternatives to the battery support portions of the electrical component20 illustrated in FIGS. 1-49 that have battery support portions forsupporting power tool batteries other than slide-on power toolbatteries.

It should also be understood that the battery charger 37H and chargerreceptacle 708 can be a variety of shapes and sizes as long as thebattery charger 37H and charger receptacle 708 have a complementaryshape and size.

It should be understood that, in some constructions, the receptacle 708may be configured to receive and store other equipment when a charger37H is not supported in the receptacle 708.

Another alternative construction of an electrical component 201 isillustrated in FIGS. 52-53. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-51. Common elements are identifiedby the same reference numbers “I”.

The electrical component 20I includes a pair of bumpers 720 extendingfrom the rear surface of the housing 24I and are designed to have impactabsorbing characteristics which protect the electrical component 20Ifrom impacts at a jobsite. The electrical component 20I also defines twocharger receptacles 708I in the rear surface of the housing 24I forreceiving the pair of battery chargers 37I. The battery chargers 37I andcharger receptacles 708I in this construction are similar to the batterycharger 37H and charger receptacle 708 of the electrical component 20Hillustrated in FIGS. 50 and 51. Accordingly, reference is made to thediscussion above regarding structure, operation, and alternatives of theelectrical component 20H illustrated in FIGS. 50 and 51.

It should be understood that, in some constructions, another electricaldevice, such as, for example, another audio component, may besubstituted for one or both of the battery chargers 37I.

It should be understood that, in some constructions, each receptacle708I may be configured to receive and store other equipment when acharger 37I is not supported in the receptacle 708I.

It should be understood that any of the constructions of the electricalcomponent 20 discussed herein and illustrated in any of the figures caninclude any number of battery chargers 37 for charging a correspondingnumber of batteries.

Two other alternative constructions of an electrical component 20J, 20Kare illustrated in FIGS. 54 and 55, respectively. Reference is made tothe above discussion regarding the structure, operation, andalternatives of the electrical component 20 illustrated in FIGS. 1-53.Common elements are identified by the same reference numbers “J” and“K”, respectively. The electrical components 20J and 20K may include oneor more battery chargers (not shown) similar to the battery chargers 37,37G, 37H and 37I, as described above.

Another alternative construction of an electrical component 20L isillustrated in FIG. 56. Reference is made to the above discussionregarding the structure, operation, and alternatives of the electricalcomponent 20 illustrated in FIGS. 1-55. Common elements are identifiedby the same reference numbers “L”.

The electrical component 20L includes a housing 24L having a firstportion 724 and a second portion 728 pivotably connected to one anothergenerally in the form of a briefcase, suitcase, tool box, etc. In theillustrated construction, the first portion 724 and the second portion728 are designed to have impact absorbing characteristics which protectthe electrical component 20L from impacts at a jobsite, such as fromfalling from a height or having another object impact the electricalcomponent 20L, which might normally damage the elements of theelectrical component 20L, such as, for example, the elements of theelectrical circuit 28L, and/or create an electrical hazard in theelectrical component 20L. For example, the first portion 724 and thesecond portion 728 may be formed of energy/impact absorbing materials,such as, for example, high-density polyethylene (HDPE), and/or formedwith energy/impact absorbing structures, such as, for example, bars,base edges, bumpers, bushings, ribs, honeycombs, energy-absorbingshapes, etc.

The electrical component 20L has an open position (the left perspectiveview in FIG. 56) and a closed position (the right perspective view inFIG. 56). The speakers 628L are supported in the first portion 724 ofthe housing 24L, and the battery connection assembly 616L, the batterycharger 37L, and the control portion 620L are supported in the secondportion 728 of the housing 24L. In the illustrated construction, thereceptacle 44L of the battery connection assembly 616L is large enoughto support multiple batteries 70L. In some constructions, only one ofthe batteries 70L is electrically connected to the electrical component20L by the electrical connector assembly 144L. In other constructions,multiple batteries 70L are connected to the electrical component 20L bymultiple electrical connector assemblies 144L. In such constructions, anactuator 236L is operable to disconnect either one or both of thebatteries 70L from the electrical connector assemblies 144L. Theelectrical component 20L may include additional receptacles (not shown)to support and retain other equipment, such as, for example, a powertool, a power tool accessory (e.g., drill bits, saw blades, lights,etc.), additional audio components (e.g., an auxiliary audio deviceconnectable with the audio circuit), electronic devices (e.g., a cellphone, a PDA, etc.), etc.

In the illustrated construction, the battery charger 37L is selectivelyconnectable to the housing 24L in a manner similar to the batterycharger 37 of the electrical component 20 illustrated in FIGS. 1-55.Reference is made to the above discussion regarding the structure,operation, and alternatives of the battery charger 37 of the electricalcomponent 20 illustrated in FIGS. 1-55.

Also, in the illustrated construction, a pair of locking or latchingmembers 67L are operable to lock the first portion 724 and the secondportion 728 together, thereby locking the electrical component 20L inthe closed position. Any number of latching members 67L can be used tolock the first portion 724 to the second portion 728.

Although particular constructions of the present invention have beenshown and described, other alternative constructions will be apparent tothose skilled in the art and are within the intended scope of thepresent invention. Thus, the present invention is to be limited only bythe claims.

1.-20. (canceled)
 21. An audio and charging system comprising: a powercord including a device end and an outlet end, the outlet end includinga plug housing with conductors that are operable to connect to an outletand receive power; an audio device including a device housing, a cordconnector configured to be coupled to the device end of the power cord,a power tool battery receptacle electrically connectable to the powercord, and an audio circuit within the device housing and operable toproduce an audio signal, the audio circuit being selectivelyelectrically connectable to the power cord and to a power tool batterywithin the power tool battery receptacle; and a battery charger externalto the device housing and including a charging circuit operable toreceive power via the conductors of the outlet end and to charge thebattery within the power tool battery receptacle via the device end ofthe power cord.
 22. The audio and charging system of claim 21, whereinthe battery charger is positioned within the plug housing.
 23. The audioand charging system of claim 21, wherein the battery charger is within abattery charger housing positioned along the power cord between thedevice end and the outlet end.
 24. The audio and charging system ofclaim 21, wherein the cord connector and device end are removablycoupled together via one of a plug-type connection and a quick-lockconnection.
 25. The audio and charging system of claim 21, furthercomprising a receptacle cover coupled to the device housing, wherein thereceptacle cover includes an open position allowing removal andinsertion of the power tool battery and a closed position preventingremoval and insertion of the power tool battery.
 26. The audio andcharging system of claim 25, wherein the receptacle cover is pivotablycoupled to the device housing.
 27. The audio and charging system ofclaim 25, wherein the receptacle cover includes a biasing member that,when the receptacle cover is in the closed position, biases the powertool battery into the power tool battery receptacle.
 28. An audio andcharging system comprising: a power cord including a device end and anoutlet end, the outlet end including a plug housing with conductors thatare operable to connect to an outlet and receive power, the plug housingincluding a charging circuit operable to receive power via theconductors and to provide charging power via the device end of the powercord; and an audio device including a device housing, a cord connectorconfigured to be coupled to the device end of the power cord, a powertool battery receptacle electrically connectable to the power cord toreceive the charging power from the charging circuit, and an audiocircuit within the device housing and operable to produce an audiosignal, the audio circuit being selectively electrically connectable tothe power cord and to a power tool battery within the power tool batteryreceptacle.
 29. The audio and charging system of claim 28, wherein thecord connector and device end are removably coupled together via one ofa plug-type connection and a quick-lock connection.
 30. The audio andcharging system of claim 28, further comprising a receptacle covercoupled to the device housing, wherein the receptacle cover includes anopen position allowing removal and insertion of the power tool batteryand a closed position preventing removal and insertion of the power toolbattery.
 31. The audio and charging system of claim 30, wherein thereceptacle cover is pivotably coupled to the device housing.
 32. Theaudio and charging system of claim 30, wherein the receptacle coverincludes a biasing member that, when the receptacle cover is in theclosed position, biases the power tool battery into the power toolbattery receptacle.
 33. An audio and charging system comprising: a powercord including a device end and an outlet end, the outlet end includinga plug housing with conductors that are operable to connect to an outletand receive power; an audio device including a device housing, a cordconnector configured to be coupled to the device end of the power cord,a power tool battery receptacle electrically connectable to the powercord, and an audio circuit within the device housing and operable toproduce an audio signal, the audio circuit being selectivelyelectrically connectable to the power cord and to a power tool batterywithin the power tool battery receptacle; and a battery chargerpositioned along the power cord external to the device housing, thebattery charger including a charging circuit operable to receive powervia the conductors of the outlet end and to charge the power toolbattery within the power tool battery receptacle via the device end ofthe power cord.
 34. The audio and charging system of claim 28, whereinthe cord connector and device end are removably coupled together via oneof a plug-type connection and a quick-lock connection.
 35. The audio andcharging system of claim 28, further comprising a receptacle covercoupled to the device housing, wherein the receptacle cover includes anopen position allowing removal and insertion of the power tool batteryand a closed position preventing removal and insertion of the power toolbattery.
 36. The audio and charging system of claim 30, wherein thereceptacle cover is pivotably coupled to the device housing.
 37. Theaudio and charging system of claim 30, wherein the receptacle coverincludes a biasing member that, when the receptacle cover is in theclosed position, biases the power tool battery into the power toolbattery receptacle.